8mm Raw Copper Rod To 1.2-4.0mm Wire Breakdown Drawing Machine for Cable Production

1. General description

The copper rod breakdown machine is a high-performance continuous cold drawing solution tailored for the wire and cable industry. It is designed to process standard Φ8mm copper rods into precision bare copper single wires ranging from 1.2mm to 4.0mm. Serving as essential front-end processing equipment in copper wire production lines, it delivers consistent, high-quality wire stock for power cables, communication cables, automotive wiring harnesses, motor windings and various electrical components.

2. Working Principle

This machine adopts advanced room-temperature continuous cold forming technology. Raw copper rods pass sequentially through a series of precision tungsten carbide drawing dies with progressively reduced apertures, achieving gradual sectional compression and linear elongation. A closed circulating lubrication and cooling system effectively minimizes frictional resistance and operational heat. The integrated closed-loop tension control system synchronizes the running speed of all drawing capstans, eliminating wire breakage, dimensional deviation and surface flaws. The optional online annealing module softens work-hardened copper wire, restoring optimal electrical conductivity and flexibility for downstream manufacturing procedures.

3. Main Structure & Core Components

3.1. Automatic Pay-off System

Fitted with a heavy-duty vertical motorized pay-off stand, this system enables steady, tangle-free and uninterrupted feeding of Φ8mm copper rods. It features ultra-stable tension output and excellent adaptability, supporting long-cycle continuous production without manual interruption.

3.2. High-precision Drawing Host

The drawing capstans are constructed from high-strength cast steel with specialized wear-resistant surface treatment, delivering exceptional structural rigidity, low operational vibration and extended service life. Matched with multi-stage high-precision drawing dies, the equipment guarantees precise dimensional tolerance and superior wire surface smoothness. Independent frequency conversion speed regulation realizes accurate speed matching for each drawing pass, ensuring consistent forming quality.

3.3. Circulating Cooling & Lubrication System

The fully enclosed circulating lubrication system provides comprehensive cooling and lubrication for drawing dies and running copper wires during operation. It significantly reduces die abrasion and surface scratches, greatly improving the surface finish of finished products. The cyclic oil recycling design minimizes material consumption and effectively lowers overall production costs.

3.4. Optional Online Annealing System

Adopting low-voltage high-current continuous annealing technology, the system achieves uniform and stable softening treatment of copper wires. Annealed wires feature consistent resistivity, excellent flexibility and uniform mechanical properties, fully meeting the manufacturing standards of high-grade soft copper wires.

3.5. Dual Take-up System

Equipped with a dual-spool automatic winding structure paired with precision traversing and constant tension control technology, the machine ensures neat, compact and deformation-free wire coiling. It supports automatic spool switching to enable non-stop 24-hour production, substantially boosting operational efficiency and output capacity.

3.6. Intelligent PLC Control System

Featuring a user-friendly touchscreen HMI, the intelligent PLC control system supports one-click parameter configuration, real-time operational data monitoring and automatic fault diagnosis and alarm. Full digital frequency conversion control ensures stable equipment operation, intuitive operation logic and ultra-low failure rate.

4. Product Advantages

- Stable High Productivity: Featuring a maximum line speed of 25m/s, the machine supports continuous and high-efficiency production, delivering superior output capacity ideal for large-scale industrial mass production.

- Premium Wire Quality: Precision closed-loop tension control and high-precision forming dies ensure ultra-tight dimensional tolerance, burr-free smooth surface, and stable tensile strength and electrical conductivity of finished copper wires.

- Robust Durability & Easy Maintenance: The integral rigid machine frame and wear-resistant transmission components reduce operational vibration and mechanical loss. Modular structural design simplifies daily maintenance and quick replacement of wearing parts, lowering downtime.

- Energy-saving & Cost-efficient: Optimized variable-frequency energy-saving technology cuts power consumption effectively. The circulating lubrication system reduces material waste, delivering outstanding long-term operational cost performance.

- Wide Compatibility: It covers full production of copper wires from 1.2mm to 4.0mm. Flexible parameter adjustment enables fast specification switching to meet diverse production demands.

5. Technical Parameters

- Inlet wire diameter: Φ8mm standard copper rod

- Outlet wire diameter: Φ1.2mm – Φ4.0mm

- Max running speed: 25m/s

- Drawing passes: 9–13 passes

- Take-up spool type: 500/630 type

- Control mode: PLC full digital frequency conversion control

- Optional function: Online continuous annealing

6. Application Range

This equipment produces high-quality bare copper single wires widely adopted in power distribution cables, communication cables, household electrical wires, automotive wiring, as well as motor and transformer winding wires. The finished wires perfectly support downstream processes including stranding, extrusion insulation and tin plating.

7. Operation & Maintenance Precautions

7.1. Operation Precautions

- Only professionally trained operators are permitted to operate the equipment. Unauthorized personnel are strictly prohibited from starting, adjusting or maintaining the machine to prevent personal safety hazards and equipment malfunctions.

- Prior to startup, conduct a comprehensive inspection of circuit systems, lubrication units, drawing dies, tension sensors and safety protective devices. Ensure no looseness, oil leakage or component damage; start the machine only after all inspection items confirm normal status.

- During machine operation, keep hands, tools and foreign objects away from rotating capstans, wire running paths and winding mechanisms to avoid clamping and scratching injuries.

- Parameter adjustment, die replacement and component disassembly are forbidden during operation. Always stop the machine completely and cut off the power supply before any modification or maintenance work.

- In case of abnormal noise, wire breakage, oil leakage or emergency shutdown during operation, stop the machine immediately for inspection. Resume production only after all faults are fully resolved to prevent secondary equipment damage.

- Produce strictly in accordance with the rated wire specification and speed range. Overload operation and long-term over-speed operation are prohibited to prolong the equipment’s service life.

7.2. Daily & Regular Maintenance

- Daily Maintenance: Clean wire residues and surface dust before and after operation. Check lubricant level and cleanliness, replenish or replace lubricant timely to ensure stable cooling and lubrication performance. Verify the sensitivity of tension control and fault alarm systems.

- Weekly Maintenance: Fasten loose bolts and transmission components. Inspect the wear condition of drawing dies and guide wheels, replace severely worn parts promptly. Clean lubrication system filters to prevent blockage and ensure smooth oil circulation.

- Monthly Maintenance: Inspect the operating status of motors, inverters and PLC control systems. Calibrate wire dimensional accuracy and tension control parameters. Check the sealing performance of lubrication units to eliminate potential oil leakage risks.

- Long-term Shutdown Maintenance: Conduct thorough overall cleaning of the machine. Drain residual circulating lubricant, apply anti-rust treatment on metal wearing parts, cover the equipment with a dust cover, and cut off the total power supply to avoid moisture corrosion and component damage.

7.3. Environmental & Safety Notes

- The equipment must be installed in a dry, ventilated and dust-free workshop environment. Avoid long-term exposure to humid, high-temperature and corrosive atmospheres to prevent circuit aging and metal corrosion.

- Reliable equipment grounding is mandatory to ensure electrical safety and eliminate static electricity and electric leakage risks during long-term continuous operation.

- Waste lubricant and discarded wearing parts must be sorted and disposed of in compliance with local environmental protection regulations; arbitrary dumping is strictly prohibited.